Mitsubishi Fuso FH Series 1992-2001 Factory Service & Shop Manual
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Complete workshop repair service manual with electrical wiring diagrams for Mitsubishi Fuso FH Series 1992-2001 Trucks. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.
Mitsubishi Fuso FH Series 1992-2001 Trucks service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.
3,100+ pages, bookmarked, Searchable, Printable, high quality PDF
FH Series 1992-1995 Fuso Service Manual (TWME9106 - 1,536 pages).pdf
FH Series 1996-2001 Fuso Service Manual (TWME9502 - 1,652 pages).pdf
EXCERPT:
TABLE OF CONTENTS
GROUP INDEX
GENERAL .. 00
MAINTENANCE SCHEDULE .. 01
ENGINE.. 11
LUBRICATION .. 12
FUEL AND ENGINE CONTROL.. 13
COMMON RAIL SYSTEM.. 13E
COOLING.. 14
INTAKE AND EXHAUST .. 15
EMISSION CONTROL .. 17
BlueTec® SYSTEM .. 17E
CLUTCH.. 21
TRANSMISSION .. 22
DUONIC TM .. 22E
TRANSFER .. 24
PROPELLER SHAFT .. 25
FRONT AXLE
.. 26A
.. 26B
REAR AXLE.. 27
WHEEL AND TIRE .. 31
FRONT SUSPENSION .. 33
REAR SUSPENSION.. 34
BRAKE.. 35
ANTI-LOCK BRAKE SYSTEM (ABS) .. 35E
PARKING BRAKE .. 36
STEERING .. 37
BUMPER AND FRAME .. 41
CAB.. 42
DOOR.. 43
EXTERIOR .. 51
INTERIOR .. 52
ELECTRICAL.. 54
HEATER, AIR-CONDITIONER
AND VENTILATION .. 55
FULL AUTOMATIC
AIR-CONDITIONER .. 55E
..
GR00 GENERAL...1
GR00 MC97 1997 MODEL CHANGES...44
GR00 MC98 1998 MODEL CHANGES...54
GR00 MC99 1999 MODEL CHANGES...70
GR00 MC00 2000 MODEL CHANGES...109
GR00 MC01 2001 MODEL CHANGES...160
GR01 MAINTENANCE SCHEDULE...190
GR01 MC98 MAINTENANCE SCHEULE '98 MINOR CHENGES...234
GR10 REMOVE AND INSTALLATION OF ENGINE...278
GR11 ENGINE...286
GR12 LUBRICATION...345
GR13 FUEL AND ENGINE CONTROL...369
GR13 MC99 FUEL AND ENGINE CONTROL '99 MINOR CHANGES...447
GR14 COOLING...535
GR15 INTAKE AND EXHAUST...559
GR21 CLUTCH...581
GR22 MANUAL TRANSMISSION...613
GR22 MC00 2000 MANUALTRSMISSION M050S5, S6 MINOR CHANGES...673
GR23 AUTOMATIC TRANSMISSION...738
GR25 PROPELLER SHAFT...768
GR26 FRONT AXLE...783
GR27 REAR AXLE...807
GR31 WHEEL AND TIRE...847
GR33 FRON SUSPENSION...855
GR34 REAR SUSPENSION...871
GR35 BRAKE...885
Group 35 - Brake...885
Table of Contents...886
Specifications...887
Structure and Operation...889
Troubleshooting...911
Inspection and Adjustment Mounted In Mounted In Vehicle...915
Handling of Connectors...922
Brake Pedal...923
Dual Brake Valve...927
Brake Booster (Airmaster)...934
Front Wheel Brake...941
Rear Wheel Brake...949
Air Compressor...957
Air Dryer...965
Air Pressure Governor...969
Fluid Tank...971
Check Valve/Safety Valve...972
Supply Valve...973
Exhaust Brake System...975
GR35 MC98 BRAKE 1998 MINOR CHANGES...982
GR35A ANTI-LOCK BRAKE SYSTEM ABS 2000 MINOR CHANGES...1049
GR36 PARKING BRAKE...1085
GR37 STEERING...1101
GR37 MC98 STEERING 1998 MINOR CHANGES...1145
GR41 FRAME...1195
GR42 CAB...1202
GR54 ELECTRICAL...1258
GR54 MC98 ELECTRICAL 1998 MINOR CHANGES...1498
GR55A AIR-CONDITIONER...1602
GR55B HEATER...1636
92-95 FH Service Manual...1
Manual Layout...2
Group 00 - General...4
Group 00 - General (Supplement)...5
Group 00 - General ('95 Minor Change)...22
Group 00 - General ('94 Minor Change)...30
Group 00 - General ('93 Minor Change)...36
Group 00 - General...42
Table of Contents...43
1. External Views...44
2. Major Specifications...49
3. Power Train Table...52
4. Equipment Model Notation...52
5. Performance Curves...53
5.1 Operation Performance Curves...53
5.2 Engine Performance Curves...53
6. Servicing Precautions...53
7. Standard Bolts and Nuts Tightening Torque Table...60
8. Towing Precautions...61
9. Chassis and Engine Numbers...62
10. Vehicle Identification Number...62
Group 01 - Maintenance Schedule...64
Table of Contents...65
1. How to Read the Maintenance Schedule Tables...66
2. Maintenance Schedule Tables...67
3. Maintenance Operations...73
3.1 Replacement of the Engine Oil Filter Element...73
3.2 Replacement of the Fuel Filter Element...73
3.3 Inspection of Air Dryer...74
3.4 Cleaning of the Fuel Feed Pump Gauze Filter...74
3.5 Bleeding Air from the Fuel Line...74
3.6 Water Separator Condensation Drain...75
3.7 Adjusting V-Belt Tension...75
3.8 Cleaning and Replacement of the Air Cleaner Element...76
3.9 Inspecting the Clutch Pedal <Vehicles with Manual Transmission>...77
3.10 The Tires...78
3.10.1 Air Pressure...78
3.10.2 Removing Tires...78
3.10.3 Tire Mounting...79
3.10.4 Checking the Wheel Nuts for Looseness...81
3.10.5 Tire Rotation...81
3.11 Adjusting the Clearance of the Wheel Brake Shoe...82
3.12 Adjusting the Clearance of the Parking Brake Shoe...83
3.13 The Battery...83
3.14 Fuses...85
4. Lubrication...89
4.1 Engine Oil...90
4.2 Gear Oil for Manual Transmission...91
4.3 Automatic Transmission Fluid and Oil Filters for Automatic Transmission...92
4.4 Rear Axle Gear Oil...95
4.5 Power Steering Fluid...96
4.6 Brake Fluid...100
4.6.1 Brake Fluid Tank...100
4.6.2 Clutch Fluid Tank...103
4.7 Greasing the Various Areas of the Chassis...106
Group 11 - Engine...107
Table of Contents...108
1. Troubleshooting...110
2. Engine Removal and Installation (Manual Transmission Vehicles)...113
2.1 Service Standards...113
2.1.1 Tightening Torque Table...113
2.2 Removal of Engine and Transmission...113
2.2.1 Preparation for Removal...113
2.2.2 Removal of Harness...114
2.2.3 Removal of Air Compressor Hoses, Actuator and Tube Assembly...116
2.2.4 Removal of Parts Around the Engine...116
2.2.5 Removal of Engine Parts...117
2.2.6 Removal of Transmission Parts...119
2.2.7 Removal of Transmission...121
2.2.8 Removing the Engine from the Vehicle...121
2.3 Installation of the Engine and Transmission...122
2.3.1 Installation of Engine...122
2.3.2 Installation of Transmission...123
2.3.3 Installation of Transmission Parts...123
2.3.4 Installation of Engine Parts...125
2.3.5 Installation of Parts Around the Engine...126
2.3.6 Installation of Air Compressor Hoses, Actuator and Tube Assembly...127
2.3.7 Installation of Harness...128
2.4 Adjustment After Installation...129
2.4.1 Preparation for Adjustment...129
2.4.2 Adjustment...131
3. Engine Removal and Installation (Automatic Transmission Vehicles)...132
3.1 Service Standards...132
3.1.1 Tightening Torque Table...132
3.2 Removal of Engine and Transmission...132
3.2.1 Preparation for Removal...132
3.2.2 Removal of Harness...133
3.2.3 Removal of Air Compressor Hose...134
3.2.4 Removal of Parts Around the Engine...135
3.2.5 Removal of Engine Parts...136
3.2.6 Removal of Transmission Parts...138
3.2.7 Removal of Transmission...140
3.2.8 Removing the Engine from the Vehicle...140
3.3 Installation of the Engine and Transmission...141
3.3.1 Installation of the Engine...141
3.3.2 Installation of Transmission...142
3.3.3 Installation of Transmission Parts...143
3.3.4 Installation of Engine Parts...144
3.3.5 Installation of Parts Around the Engine...145
3.3.6 Installation of Air Compressor Hose...146
3.3.7 Installation of Harnesses...146
3.4 Adjustment After Installation...148
3.4.1 Preparation for Adjustment...148
3.4.2 Adjustment...150
4. Engine Assembly...151
4.1 Specifications...151
4.2 Service Standards...151
4.2.1 Service Standards Table...151
4.2.2 Tightening Torque Table...152
4.2.3 Special Tools Table...152
4.3 Inspection and Adjustment of Valve Clearance...154
4.4 Measurement of Compression Pressure...155
4.5 Inspection of Oil Pressure...157
4.6 Inspection and Adjustment of Fuel Injection Start Timing...157
4.7 Bleeding the Fuel System...158
4.8 Inspection and Adjustment of V-Belt Tension...159
4.9 Measurement of Turbocharger Boost Pressure...160
5. Cylinder Head and Valve Mechanism...163
5.1 Service Standards...163
5.1.1 Service Standards Table...163
5.1.2 Tightening Torque Table...163
5.1.3 Special Tools Table...164
5.2 General Description...166
5.2.1 Cylinder Head...166
5.2.2 Valve Mechanism...166
5.3 Removal...167
5.4 Disassembly...169
5.4.1 Rocker and Bracket Assembly...169
5.4.2 Cylinder Head Assembly...169
5.5 Inspection...171
5.6 Reassembly...179
5.6.1 Cylinder Head Assembly...179
5.6.2 Rocker and Bracket Assembly...181
5.7 Installation...182
6. Flywheel and Flywheel Housing (Manual Transmission Vehicles)...185
6.1 Service Standards...185
6.1.1 Service Standards Table...185
6.1.2 Tightening Torque Table...185
6.1.3 Special Tools Table...185
6.1.4 Sealant Table...185
6.2 General Description...186
6.3 Disassembly...186
6.4 Inspection...187
6.5 Reassembly...189
7. Flywheel and Flywheel Housing (Automatic Transmission Vehicles)...194
7.1 Service Standards...194
7.1.1 Tightening Torque Table...194
7.1.2 Special Tools Table...194
7.1.3 Sealant Table...194
7.2 General Description...195
7.3 Disassembly...195
7.4 Inspection...196
7.5 Reassembly...197
8. Timing Gear and Camshaft...201
8.1 Service Standards...201
8.1.1 Service Standards Table...201
8.1.2 Tightening Torque Table...201
8.1.3 Lubricant Table...201
8.1.4 Sealant Table...201
8.1.5 Special Tools Table...202
8.2 General Description...203
8.3 Disassembly...204
8.4 Inspection...207
8.5 Reassembly...211
9. Crankcase and Main Moving Parts...214
9.1 Service Standards...214
9.1.1 Service Standards Table...214
9.1.2 Tightening Torque Table...215
9.1.3 Sealant Table...215
9.1.4 Special Tools Table...215
9.2 General Description...216
9.2.1 Crankshaft...216
9.2.2 Connecting Rod...217
9.2.3 Piston...217
9.3 Disassembly...218
9.4 Inspection...222
9.5 Reassembly...233
Group 12 - Lubrication...240
Table of Contents...241
1. Troubleshooting...242
2. Lubrication System...242
2.1 Specifications...242
2.2 General Description...243
2.2.1 System Outline...243
2.2.2 Lubrication of Main Moving Parts...244
2.2.3 Camshaft Lubrication...244
2.2.4 Valve Mechanism Lubrication...244
2.2.5 Timing Gear Lubrication...245
2.2.6 Turbocharger Lubrication...245
2.2.7 Injection Pump Assembly Lubrication...246
2.2.8 Air Compressor Lubrication...246
2.3 Oil Pressure Check...246
3. Oil Pan and Oil Strainer...247
3.1 Service Standards...247
3.1.1 Tightening Torque Table...247
3.1.2 Sealant Table...247
3.2 General Description...247
3.3 Removal...247
3.4 Installation...248
3.5 Post-Installation Inspection...250
4. Oil Pump...251
4.1 Service Standards...251
4.1.1 Service Standards Table...251
4.2 General Description...251
4.3 Removal...251
4.4 Disassembly and Inspection...252
4.5 Reassembly...255
4.6 Installation...256
5. Oil Cooler and Oil Filter...257
5.1 Service Standards...257
5.1.1 Service Standards Table...257
5.1.2 Tightening Torque Table...257
5.1.3 Special Tools Table...257
5.2 General Description...258
5.3 Removal...259
5.4 Disassembly and Inspection...260
5.5 Reassembly...261
5.6 Installation...262
Group 13 - Fuel and Engine Control...264
Table of Contents...265
1. Troubleshooting...266
2. Fuel System...268
2.1 General Description...268
2.2 Removal and Installation of the Fuel Hoses...269
3. Prestroke Control Type Injection Pump System...270
3.1 Specifications...270
3.2 Service Standards...270
3.2.1 Service Standards Table...270
3.2.2 Tightening Torque Table...271
3.2.3 Special Tools Table...271
3.3 General Description...272
3.3.1 Prestroke Control Type Injection Pump System...272
3.3.2 Control Unit...275
3.3.3 Sensors...276
3.3.4 Injection Pump Proper...277
3.3.5 Governor...279
3.3.6 Feed Pump...284
3.3.7 Coupling...285
3.4 Service Procedure...285
3.4.1 Inspection of System...288
3.4.2 Removal of Injection Pump Assembly...309
3.4.3 Installation of Injection Pump Assembly...311
3.4.4 Adjustments After Installation of Injection Pump...314
3.4.5 Bleeding Air from the Fuel System...314
3.4.6 Adjustment of Fuel Injection Timing...314
3.4.7 Adjustment of No-Load Minimum and Maximum Speeds...315
3.4.8 Operation Check of the Engine Stop Cable...315
4. Injection Nozzles...316
4.1 Specifications...316
4.2 Service Standards...316
4.2.1 Service Standards Table...316
4.2.2 Tightening Torque Table...316
4.3 General Description...317
4.4 Removal...317
4.5 Disassembly...317
4.6 Inspection and Cleaning...319
4.7 Reassembly...320
4.8 Test and Adjustment...322
4.9 Installation...323
5. Fuel Filter...324
5.1 Specifications...324
5.2 Service Standards...324
5.2.1 Tightening Torque Table...324
5.2.2 Special Tools Table...324
5.3 General Description...325
5.4 Removal and Inspection...325
5.5 Installation...325
6. Water Separator...327
6.1 Specifications...327
6.2 Service Standards...327
6.3 General Description...327
6.4 Removal...327
6.5 Disassembly and Inspection...328
6.6 Reassembly...328
6.7 Installation...329
6.8 Draining Water...329
7. Fuel Tank...330
7.1 Specifications...330
7.2 Service Standards...330
7.3 General Description...330
7.4 Removal...330
7.5 Inspection...332
7.6 Installation...332
8. Engine Control System...334
8.1 Specifications...334
8.2 Service Standards...335
8.3 General Description...336
8.4 Removal...337
8.4.1 Disconnecting the Accelerator Control Cable and Engine Stop Cable...337
8.4.2 Removal of the Throttle Cable...340
8.4.3 Removal of the Accelerator Pedal and Accelerator Lever Assembly...342
8.5 Inspection...343
8.6 Installation...343
8.6.1 Installation of Accelerator Lever Assembly and Accelerator Pedal...344
8.6.2 Installation of Throttle Cable...345
8.6.3 Installation of Accelerator Control Cable and Engine Stop Cable...347
8.7 Adjustment After Installation...351
8.7.1 Adjustment of the Accelerator Pedal Stopper...351
8.7.2 Operation Check of the Engine Stop Cable...352
8.7.3 Adjustment of the Accelerator Switch (Exhaust Brake Microswitch)...352
Group 14 - Cooling...354
Table of Contents...355
1. Troubleshooting...356
2. Cooling System...357
2.1 Specifications...357
2.2 General Description...357
2.3 Removal...358
2.3.1 Preparation for Removal...358
2.3.2 Radiator and Reservoir Tank Removal...358
2.3.3 Cooling Fan and Auto-Cool Fan Coupling Removal...360
2.3.4 Water Pump Removal...361
2.3.5 Thermostat Removal...361
2.4 Installation...362
2.4.1 Thermostat Installation...362
2.4.2 Water Pump Installation...363
2.4.3 Cooling Fan and Auto-Cool Fan Coupling Installation...364
2.4.4 Radiator and Reservoir Tank Installation...364
2.4.5 Operations After Installation...366
3. Cooling Fan and Auto-Cool Fan Coupling...367
3.1 General Description...367
3.1.1 Cooling Fan...367
3.1.2 Auto-Cool Fan Coupling...367
3.2 Auto-Cool Fan Coupling Inspection...369
4. Thermostat...370
4.1 Service Standards...370
4.1.1 Service Standards Table...370
4.2 General Description...370
4.3 Inspection...370
5. Radiator...371
5.1 Service Standards...371
5.2 General Description...371
5.2.1 Radiator...371
5.2.2 Pressure Cap...371
5.2.3 Radiator Shroud...372
5.2.4 Reservoir Tank...372
5.3 Inspection and Cleaning...372
5.3.1 Radiator Cleaning...372
5.3.2 Radiator Inspection...373
5.3.3 Pressure Cap Inspection...373
5.3.4 Radiator (Cooling System) Cleaning...374
5.3.5 Gas Leak Test...376
5.3.6 Cooling System Air Bleeding...377
Group 15 - Intake and Exhaust...378
Table of Contents...379
1. Troubleshooting...380
2. Intake System...381
2.1 Specifications...381
2.2 Service Standards...381
2.2.1 Service Standards Table...381
2.2.2 Tightening Torque Table...381
2.3 General Description...381
2.4 Removal...383
2.5 Air Cleaner Disassembly, Cleaning and Reassembly...384
2.5.1 Disassembly...384
2.5.2 Cleaning...385
2.5.3 Reassembly...386
2.6 Installation...386
2.7 Intake System Inspection...388
3. Exhaust System...389
3.1 Service Standards...389
3.2 General Description...389
3.3 Removal...390
3.4 Inspection...391
3.5 Installation...392
3.6 Exhaust System Inspection...395
4. Turbocharger...396
4.1 Specifications...396
4.2 Service Standards...396
4.2.1 Service Standards Table...396
4.2.2 Tightening Torque Table...396
4.2.3 Lubricant Table...397
4.3 General Description...397
4.4 Removal...398
4.5 Disassembly...401
4.6 Cleaning and Inspection...406
4.6.1 Cleaning...406
4.6.2 Inspection...407
4.7 Reassembly...409
4.8 Installation...416
4.9 Post-Installation Inspection...418
5. Intercooler...419
5.1 Specifications...419
5.2 Service Standards...419
5.3 Outline...419
5.4 Removal...419
5.5 Cleaning and Inspection...420
5.6 Installation...420
6. Intake Shutter Valve System <Vehicles with Manual Transmission>...421
6.1 Specifications...421
6.2 Service Standards...421
6.2.1 Service Standards Table...421
6.2.2 Tightening Torque Table...421
6.3 General Description...422
6.4 Removal...423
6.5 Inspection...424
6.6 Installation...424
Group 16 - Engine Electrical...426
Table of Contents...427
1. Troubleshooting...428
2. Electrical System...430
2.1 Specifications...430
2.2 General Description...431
2.2.1 Starting System...433
2.2.2 Charging System...438
3. Starter...439
3.1 Service Standards...439
3.1.1 Service Standards Table...439
3.1.2 Lubricant...439
3.2 General Description...440
3.3 Removal...441
3.4 Disassembly...443
3.5 Inspection...446
3.6 Reassembly...454
3.7 Testing...459
3.8 Installation...461
4. Alternator...462
4.1 Service Standards...462
4.1.1 Service Standards Table...462
4.1.2 Tightening Torque Table...462
4.1.3 Lubricant Table...462
4.2 General Description...463
4.3 Removal...466
4.4 Disassembly...467
4.5 Inspection...470
4.6 Reassembly...474
4.7 Testing...477
4.7.1 Handling Precautions...477
4.7.2 Performance Testing...478
4.7.3 Regulator Inspection...479
4.8 Installation...480
5. Glow System...482
5.1 Service Standards...482
5.1.1 Service Standards...482
5.1.2 Tightening Torque Table...482
5.1.3 Special Tools Table...482
5.2 General Description...483
5.3 Removal...485
5.4 Inspection...486
5.4.1 Glow Plug Inspection...486
5.4.2 Glow Relay Inspection...486
5.4.3 Glow Controller Inspection...487
5.5 Installation...488
Group 21 - Clutch...490
Table of Contents...491
1. Troubleshooting...492
2. Clutch Proper...495
2.1 Specifications...495
2.2 Service Standards...495
2.2.1 Service Standards Table...495
2.2.2 Tightening Torque Table...495
2.2.3 Special Tools Table...496
2.3 General Description...497
2.4 Removal...498
2.4.1 Operation Before Removal...498
2.4.2 Removal of Clutch Proper...499
2.5 Disassembly...500
2.6 Inspection...501
2.7 Reassembly...506
2.8 Installation...508
2.9 Post-Installation Adjustment...509
2.10 Lubrication of Drive Pinion Splines...509
3. Clutch Control...511
3.1 Specifications...511
3.2 Service Standards...511
3.2.1 Service Standards Table...511
3.2.2 Tightening Torque Table...512
3.2.3 Sealant Table...512
3.2.4 Special Tools Table...513
3.3 General Description...514
3.4 Clutch Hose and Piping...515
3.4.1 Removal...515
3.4.2 Inspection...519
3.4.3 Installation...520
3.4.4 Post-Installation Work...523
3.5 Clutch Pedal Assembly...524
3.5.1 Removal...524
3.5.2 Disassembly...526
3.5.3 Inspection...527
3.5.4 Reassembly...528
3.5.5 Installation...530
3.5.6 Post-Installation Adjustment...531
3.6 Clutch Master Cylinder...531
3.6.1 Removal...531
3.6.2 Disassembly...532
3.6.3 Inspection...533
3.6.4 Reassembly...533
3.6.5 Installation...534
3.6.6 Post-Installation Adjustment...534
3.7 Clutch Power Cylinder...535
3.7.1 Removal...535
3.7.2 Disassembly...536
3.7.3 Inspection...537
3.7.4 Reassembly...538
3.7.5 Installation...539
3.7.6 Post-Installation Adjustment...540
3.8 Clutch Housing Assembly...540
3.8.1 Removal...540
3.8.2 Disassembly...542
3.8.3 Reassembly...543
3.8.4 Installation...545
3.8.5 Post-Installation Adjustment...545
3.9 Fluid Change in the Clutch System...546
3.10 Bleeding the Clutch System...547
3.11 Clutch Pedal Inspection and Adjustment...548
3.12 Clutch Adjustment...549
Group 22 - Manual Transmission...552
Table of Contents...553
1. Troubleshooting...554
2. Removing and Installing...556
2.1 Service Standards...556
2.1.1 Tightening Torque Table...556
2.2 Preliminary Operations...556
2.3 Removal...557
2.4 Installation...558
3. Transmission Assembly...561
3.1 Specifications...561
3.2 Service Standards...561
3.2.1 Service Standards Table...561
3.2.2 Tightening Torque Table...561
3.2.3 Special Tools Table...562
3.2.4 Sealant Table...565
3.3 General Description...565
3.4 Removal...570
3.4.1 Clutch Housing Assembly...570
3.4.2 Gear Shift, Upper and Lower...570
3.4.3 Rear Cover and Parking Brake...570
3.4.4 Transmission...570
3.5 Installation...574
3.5.1 Transmission...574
3.5.2 Rear Cover...577
3.5.3 Gear Shift, Upper and Lower...577
3.5.4 Clutch Housing Assembly...577
4. Main Shaft Assembly...578
4.1 Service Standards...578
4.1.1 Service Standards Table...578
4.1.2 Tightening Torque Table...578
4.1.3 Special Tools Table...579
4.2 Preliminary Inspection...580
4.3 Disassembly...581
4.4 Inspection...585
4.5 Reassembly...588
5. Counter Shaft Assembly...593
5.1 Service Standards...593
5.1.1 Sealant Table...593
5.2 Special Tools Table...593
5.3 Disassembly...593
5.4 Reassembly...594
6. Reverse Gear...595
6.1 Service Standards...595
6.1.1 Service Standards Table...595
6.1.2 Tightening Torque Table...595
6.1.3 Special Tools Table...595
6.2 Disassembly and Inspection...596
6.3 Reassembly...597
7. Gear Shift, Lower...598
7.1 Service Standards...598
7.1.1 Service Standards Table...598
7.1.2 Tightening Torque Table...598
7.1.3 Sealant Table...598
7.2 General Description...599
7.3 Disassembly...600
7.4 Inspection...602
7.5 Reassembly...603
8. Gear Shift, Upper...605
8.1 Service Standards...605
8.1.1 Service Standards Table...605
8.1.2 Tightening Torque Table...605
8.1.3 Sealant Table...605
8.2 Disassembly...606
8.3 Inspection...608
8.4 Reassembly...608
9. Rear Cover...611
9.1 Service Standards...611
9.1.1 Service Standards Table...611
9.1.2 Tightening Torque Table...611
9.1.3 Special Tools Table...611
9.1.4 Sealant Table...611
9.2 Disassembly...612
9.3 Inspection...614
9.4 Reassembly...614
10. Transmission Control...617
10.1 Specifications...617
10.2 Service Standards...617
10.2.1 Service Standards Table...617
10.2.2 Tightening Torque Table...617
10.3 General Description...618
10.4 Preliminary Operations...618
10.5 Removal...618
10.6 Inspection, Repair and Replacement...620
10.7 Installation...621
10.8 Control Cable...623
10.8.1 Shift Cable...623
10.8.2 Select Cable...624
10.8.3 Inspection...624
10.9 Set Board Assembly...625
10.9.1 Disassembly and Reassembly...625
Group 23 - Automatic Transmission...626
Table of Contents...627
1. Troubleshooting...628
2. Removing and Installing...630
2.1 Specifications...630
2.2 Service Standards...630
2.2.1 Tightening Torque Table...630
2.2.2 Special Tools Table...630
2.3 Removal...631
2.4 Installation...633
3. Oil Seal and Speedometer Worm...636
3.1 Service Standards...636
3.1.1 Service Standards Table...636
3.1.2 Tightening Torque Table...636
3.1.3 Special Tools Table...636
3.2 Removal and Installation...637
3.3 Replacement of Front Oil Seal...638
3.4 Replacement of Rear Oil Seal...638
3.5 Replacement of Speedometer Worm...638
4. Automatic Transmission Control System...639
4.1 Service Standards...639
4.1.1 Service Standards Table...639
4.1.2 Tightening Torque Table...640
4.1.3 Sealant Table...640
4.2 General Description...641
4.3 Removal and Installation...643
4.4 Inspection After Installation...646
4.5 Oil Cooler...646
4.6 Fluid Pipe and Oil Temperature Sensor...647
4.7 Replacement of Fluid and Oil Filter...648
Group 25 - Propeller Shaft...651
Table of Contents...652
1. Troubleshooting...653
2. Propeller Shaft...654
2.1 Specifications...654
2.2 Service Standards...654
2.2.1 Service Standards Table...654
2.2.2 Tightening Torque Table...654
2.2.3 Special Tools Table...655
2.3 General Description...656
2.4 Removal...657
2.5 Disassembly...659
2.6 Inspection...662
2.7 Reassembly...666
2.8 Installation...670
Group 26 - Front Axle...672
Table of Contents...673
1. Troubleshooting...674
2. Front Axle Assembly...675
2.1 Specifications...675
2.2 Service Standards...675
2.2.1 Tightening Torque Table...675
2.3 General Description...676
2.4 Removal...676
2.5 Installation...677
2.6 Post-Installation Adjustment...677
3. Wheel Hub and Brake Drum...682
3.1 Service Standards...682
3.1.1 Service Standards Table...682
3.1.2 Tightening Torque Table...682
3.1.3 Sealant Table...682
3.1.4 Special Tools Table...683
3.2 Disassembly...685
3.3 Inspection...688
3.4 Reassembly...690
4. Front Axle and Knuckle...695
4.1 Service Standards...695
4.1.1 Service Standards Table...695
4.1.2 Tightening Torque Table...695
4.1.3 Special Tools Table...695
4.2 Removal...696
4.3 Disassembly...697
4.4 Inspection...699
4.5 Reassembly...702
4.6 Installation...705
Group 27 - Rear Axle...706
Table of Contents...707
1. Troubleshooting...708
2. Rear Axle Assembly...710
2.1 Specifications...710
2.2 Service Standards...710
2.2.1 Service Standards Table...710
2.2.2 Tightening Torque Table...711
2.2.3 Special Tools Table...711
2.3 General Description...712
2.4 Removal...713
2.5 Inspection...714
2.6 Installation...715
3. Wheel Hub and Brake Drums...717
3.1 Service Standards...717
3.1.1 Service Standards Table...717
3.1.2 Tightening Torque Table...717
3.1.3 Special Tools Table...717
3.2 Disassembly...720
3.3 Inspection...723
3.4 Reassembly...726
4. Reduction and Differential...733
4.1 Service Standards...733
4.1.1 Service Standards Table...733
4.1.2 Tightening Torque Table...733
4.1.3 Lubricant Table...734
4.1.4 Special Tools Table...734
4.2 Removal...737
4.3 Pre-Disassembly Inspection...738
4.4 Disassembly...740
4.5 Inspection...744
4.6 Reassembly...749
4.7 Installation...758
Group 31 - Wheels and Tires...760
Table of Contents...761
1. Troubleshooting...762
2. Wheel and Tire...763
2.1 Specifications...763
2.2 Service Standards...763
2.2.1 Service Standards Table...763
2.2.2 Tightening Torque Table...763
2.3 General Description...764
2.4 Removal...764
2.4.1 Preparation for Removal...764
2.4.2 Removing Front Tires...765
2.4.3 Removing Rear Tires...766
2.5 Removal of Tire...766
2.6 Inspection...768
2.7 Installation of Tire...769
2.8 Inspection and Adjustment After Installation...770
2.9 Installation...771
Group 33 - Front Suspension...773
Table of Contents...774
1. Troubleshooting...775
2. Front Suspension Assembly...776
2.1 Service Standards...776
2.1.1 Service Standards Table...776
2.1.2 Tightening Torque Table...776
2.1.3 Special Tools Table...777
2.2 General Description...778
2.3 Removal...778
2.4 Inspection...781
2.5 Installation...782
3. Leaf Springs...787
3.1 Specifications...787
3.2 Service Standards...787
3.3 General Description...787
3.4 Pre-Disassembly Inspection...787
3.5 Disassembly...787
3.6 Inspection...788
3.7 Reassembly...788
4. Shock Absorbers...790
4.1 Specifications...790
4.2 General Description...790
4.3 Disassembly...790
4.4 Inspection...790
5. Stabilizer...791
5.1 General Description...791
5.2 Pre-Disassembly Inspection...791
5.3 Disassembly...791
5.4 Inspection...791
5.5 Reassembly...792
Group 34 - Rear Suspension...793
Table of Contents...794
1. Troubleshooting...795
2. Rear Suspension Assembly...796
2.1 Service Standards...796
2.1.1 Service Standards Table...796
2.1.2 Tightening Torque Table...796
2.1.3 Special Tools Table...796
2.2 General Description...797
2.3 Removal...797
2.4 Inspection...800
2.5 Installation...801
3. Leaf Springs...805
3.1 Specifications...805
3.2 General Description...805
3.3 Pre-Disassembly Inspection...805
3.4 Disassembly...805
3.5 Inspection...806
3.6 Reassembly...806
4. Shock Absorbers...808
4.1 Specifications...808
4.2 General Description...808
4.3 Disassembly...808
4.4 Inspection...808
5. Stabilizer...809
5.1 General Description...809
5.2 Pre-Disassembly Inspection...809
5.3 Disassembly...809
5.4 Inspection...809
5.5 Reassembly...810
Group 35 - Brake...811
Table of Contents...812
1. Troubleshooting...814
2. Brake System...818
2.1 Specifications...818
2.2 Service Standards...818
2.2.1 Tightening Torque Table...818
2.2.2 Special Tools Table...818
2.3 General Description...819
2.4 Bleeding the Brake Fluid Lines...820
2.5 Changing the Brake Fluid...821
3. Brake Piping and Brake Fluid Tank...822
3.1 Service Standards...822
3.1.1 Tightening Torque Table...822
3.2 General Description...823
3.3 Inspection Before Removal...827
3.4 Removing the Brake Fluid...828
3.5 Removal...828
3.6 Disassembly...833
3.7 Inspection...834
3.8 Reassembly...835
3.9 Installation...836
4. Air Tank...842
4.1 Specifications...842
4.2 Service Standards...842
4.2.1 Service Standards Table...842
4.2.2 Tightening Torque Table...842
4.2.3 Sealant Table...842
4.3 General Description...843
4.4 Drain Cock...843
4.4.1 Air Leak Test...843
4.4.2 Functional Inspection...843
4.4.3 Removal...844
4.4.4 Installation...844
4.5 Safety Valve...844
4.5.1 Air Leak Test...844
4.5.2 Functional Inspection...845
4.5.3 Removal...846
4.5.4 Installation...847
4.6 Air Tank...847
4.6.1 Air Leak Test...847
4.6.2 Removal...848
4.6.3 Installation...851
5. Air Compressor...856
5.1 Specifications...856
5.2 Service Standards...856
5.2.1 Service Standards Table...856
5.2.2 Tightening Torque Table...857
5.2.3 Special Tools Table...857
5.3 General Description...858
5.4 Removal...859
5.5 Disassembly...861
5.6 Inspection...865
5.7 Reassembly...868
5.8 Installation...874
6. Brake Pedal Assembly...877
6.1 Service Standards...877
6.1.1 Service Standards Table...877
6.1.2 Tightening Torque Table...877
6.2 Removal...877
6.3 Disassembly...880
6.4 Inspection...882
6.5 Reassembly...883
6.6 Installation...884
6.7 Adjusting the Pedal Height...887
7. Dual Brake Valve...888
7.1 Specifications...888
7.2 Service Standards...888
7.2.1 Service Standards Table...888
7.2.2 Tightening Torque Table...889
7.2.3 Sealant Table...889
7.3 General Description...889
7.4 Removal...895
7.5 Disassembly...896
7.6 Inspection...902
7.7 Reassembly...904
7.8 Installation...911
8. Brake Booster (Air-Master)...914
8.1 Specifications...914
8.2 Service Standards...914
8.2.1 Service Standards Table...914
8.2.2 Tightening Torque Table...915
8.2.3 Sealant Table...915
8.3 General Description...916
8.4 Removal...919
8.5 Disassembly...923
8.6 Inspection...929
8.7 Reassembly...930
8.8 Installation...937
8.9 Inspection After Installation...943
9. Air Dryer...944
9.1 Specifications...944
9.2 Service Standards...944
9.2.1 Service Standards Table...944
9.2.2 Tightening Torque Table...944
9.2.3 Sealant Table...944
9.3 General Description...945
9.4 Maintenance and Inspection...946
9.4.1 Maintenance and Inspection...946
9.4.2 Inspection and Replacement of Desiccant...946
9.4.3 Inspection After Replacement...949
9.5 Removal...950
9.6 Disassembly...952
9.7 Reassembly...956
9.8 Inspection After Reassembly...960
9.9 Installation...960
9.10 Inspection After Installation...964
10. Air Pressure Governor...965
10.1 Specifications...965
10.2 Service Standards...965
10.2.1 Service Standards Table...965
10.2.2 Tightening Torque Table...965
10.2.3 Sealant Table...965
10.3 General Description...966
10.4 Functional Inspection...967
10.5 Adjustment...968
10.6 Removal...969
10.7 Disassembly...971
10.8 Reassembly...973
10.9 Installation...976
11. Check Valve...979
11.1 Service Standards...979
11.1.1 Service Standards Table...979
11.1.2 Tightening Torque Table...979
11.1.3 Sealant Table...979
11.2 General Description...979
11.3 Removal...980
11.4 Disassembly...980
11.5 Inspection...981
11.6 Reassembly...981
11.7 Installation...982
12. Switch...984
12.1 Specifications...984
12.2 Service Standards...984
12.2.1 Tightening Torque Table...984
12.2.2 Sealant Table...984
12.3 Stop Lamp Switch...984
12.3.1 Removal...984
12.3.2 Inspection...984
12.3.3 Installation...985
12.4 Low Air Pressure Switch...985
12.4.1 Removal...985
12.4.2 Inspection...986
12.4.3 Installation...986
13. Front Drum Brake...987
13.1 Specifications...987
13.2 Service Standards...987
13.2.1 Service Standards Table...987
13.2.2 Tightening Torque Table...988
13.2.3 Special Tools Table...988
13.3 General Description...989
13.4 Removal...989
13.5 Disassembly...990
13.6 Inspection...992
13.7 Reassembly...996
13.8 Wheel Cylinder...999
13.8.1 Disassembly...999
13.8.2 Inspection...1000
13.8.3 Reassembly...1001
13.9 Installation...1002
13.10 Adjusting Holder Pin...1004
13.11 Adjusting Shoe Clearance...1004
14. Rear Drum Brake...1006
14.1 Specifications...1006
14.2 Service Standards...1006
14.2.1 Service Standards Table...1006
14.2.2 Tightening Torque Table...1006
14.2.3 Special Tools Table...1007
14.3 General Description...1007
14.4 Removal...1007
14.5 Disassembly...1008
14.6 Inspection...1010
14.7 Reassembly...1014
14.8 Wheel Cylinder...1017
14.8.1 Disassembly...1017
14.8.2 Inspection...1018
14.8.3 Reassembly...1019
14.9 Installation...1021
14.10 Adjusting Holder Pin...1022
14.11 Adjusting Shoe Clearance...1022
15. Exhaust Brake System...1024
15.1 Specifications...1024
15.2 Service Standards...1024
15.2.1 Service Standards Table...1024
15.2.2 Tightening Torque Table...1025
15.2.3 Sealant Table...1025
15.3 General Description...1026
15.4 Removal...1028
15.5 Disassembly...1031
15.5.1 Exhaust Brake Unit...1031
15.6 Inspection...1033
15.7 Reassembly...1035
15.8 Installation...1038
15.9 Operation Test After Installing...1041
15.10 Control Cylinder...1041
15.10.1 Disassembly...1041
15.10.2 Inspection...1042
15.10.3 Reassembly...1042
15.10.4 Inspection After Assembly...1043
15.11 Supply Valve...1044
15.11.1 Disassembly...1044
15.11.2 Reassembly...1044
15.11.3 Airtightness Test After Reassembling...1045
15.11.4 Operation Test After Reassembling...1045
Group 36 - Parking Brake...1046
Table of Contents...1047
1. Troubleshooting...1048
2. Parking Brake Control...1049
2.1 Specifications...1049
2.2 Service Standards...1049
2.2.1 Service Standards Table...1049
2.2.2 Tightening Torque Table...1049
2.3 General Description...1050
2.4 Removal...1051
2.4.1 Preliminary Operation...1051
2.4.2 Parking Brake Cable...1051
2.4.3 Parking Brake Lever Assembly...1052
2.5 Disassembly and Inspection...1053
2.5.1 Disassembly...1053
2.5.2 Inspection...1054
2.6 Reassembly...1055
2.7 Installation...1056
2.7.1 Parking Brake Lever Assembly...1056
2.7.2 Parking Brake Cable...1057
2.8 Post-Installation Adjustment...1058
3. Parking Brake Drum and Shoes...1060
3.1 Specifications...1060
3.2 Service Standards...1060
3.2.1 Service Standards Table...1060
3.2.2 Tightening Torque Table...1061
3.2.3 Special Tools Table...1061
3.3 General Description...1062
3.4 Removal...1063
3.4.1 Preliminary Operation...1063
3.4.2 Removal...1063
3.5 Disassembly and Inspection...1065
3.5.1 Disassembly...1065
3.5.2 Inspection...1068
3.6 Reassembly...1070
3.7 Installation...1073
Group 37 - Steering...1076
Table of Contents...1077
1. Troubleshooting...1078
2. Power Steering System...1084
2.1 Service Standards...1084
2.1.1 Service Standards Table...1084
2.1.2 Tightening Torque Table...1084
2.2 General Description...1085
2.3 Replacement of Power Steering Fluid...1086
2.4 Performance Verification Tests...1090
2.5 Overall Checks on Power Steering...1094
3. Steering Wheel and Shaft...1097
3.1 Specifications...1097
3.2 Service Standards...1097
3.2.1 Tightening Torque Table...1097
3.3 General...1098
3.4 Removal...1098
3.5 Disassembly...1103
3.6 Reassembly...1106
3.7 Installation...1110
3.8 Inspection After Installation...1115
4. Steering Linkage...1116
4.1 Service Standards...1116
4.1.1 Service Standards Table...1116
4.1.2 Tightening Torque Table...1116
4.1.3 Special Tools Table...1116
4.2 General Description...1117
4.3 Drag Link...1118
4.3.1 Removal...1118
4.3.2 Disassembly...1118
4.3.3 Inspection and Reassembly...1118
4.3.4 Installation...1119
4.4 Tie Rod...1120
4.4.1 Removal...1120
4.4.2 Disassembly...1120
4.4.3 Inspection and Reassembly...1121
4.4.4 Installation...1123
4.5 Post-Installation Inspection and Adjustment...1123
5. Power Steering Booster...1124
5.1 Specifications...1124
5.2 Service Standards...1124
5.2.1 Service Standards Table...1124
5.2.2 Tightening Torque Table...1125
5.2.3 Sealant Table...1125
5.2.4 Special Tools Table...1126
5.3 General Description...1127
5.3.1 Construction...1127
5.3.2 Operation...1128
5.4 Removal...1130
5.5 Disassembly...1132
5.6 Inspection...1137
5.7 Reassembly...1139
5.8 Installation...1145
5.9 Post-Installation Work...1146
6. Power Steering Oil Pump...1147
6.1 Specifications...1147
6.2 Service Standards...1147
6.2.1 Service Standards Table...1147
6.2.2 Tightening Torque Table...1148
6.2.3 Special Tools Table...1148
6.3 General Description...1149
6.4 Removal...1153
6.5 Disassembly...1154
6.6 Inspection...1156
6.7 Reassembly...1159
6.8 Installation...1161
6.9 Post-Installation Inspection and Adjustment...1161
Group 41 - Frame...1162
Table of Contents...1163
1. Frame Assembly...1164
1.1 Specifications...1164
1.2 General Description...1164
1.3 Inspection and Repair...1165
1.3.1 Frame...1165
1.3.2 Rivets...1167
1.4 Frame Shape...1169
Group 42 - Cab...1173
Table of Contents...1174
1. Troubleshooting...1175
2. Cab Proper...1177
2.1 Specifications...1177
2.2 Service Standards...1177
2.3 General Description...1178
2.4 Tilting the Cab...1178
2.5 Removal...1180
2.5.1 Operation Before Removal...1180
2.5.2 Operation in the Cab...1182
2.5.3 Operation at the Cab Front...1185
2.5.4 Operation with the Cab Tilted...1188
2.5.5 Hoisting the Cab...1191
2.6 Installation...1192
2.6.1 Installing the Cab...1192
2.6.2 Operation with the Cab Tilted...1194
2.6.3 Operation from Front of the Cab...1198
2.6.4 Operation in the Cab...1201
2.6.5 Post-Installation Operation...1203
3. Cab Mounting...1205
3.1 Specifications...1205
3.2 Service Standards...1205
3.3 General Description...1206
3.3.1 Cab Mounting...1206
3.3.2 Cab Hinge...1206
3.3.3 Cab Stay...1207
3.3.4 Cab Tilt Link...1207
3.4 Cab Tilt Link...1208
3.4.1 Removal...1208
3.4.2 Installation...1210
3.4.3 Inspection and Adjustment After Installation...1212
3.5 Rear Cab Mounting...1213
3.5.1 Removal...1213
3.5.2 Installation...1216
3.5.3 Post-Installation Inspection and Adjustment...1219
3.6 Cab Hinge...1220
3.6.1 Removal...1220
3.6.2 Installation...1223
3.6.3 Post-Installation Operation...1226
4. Front Windshield Glass and Rear Window Glass...1227
4.1 Specifications...1227
4.2 Service Standards...1227
4.3 Removal...1227
4.3.1 Operation Before Removal...1227
4.3.2 Removal...1227
4.4 Installation...1228
4.4.1 Installation Operation...1228
4.4.2 Post-Installation Operation...1230
5. Door Assembly...1231
5.1 Specifications...1231
5.2 Service Standards...1231
5.3 General Description...1232
5.4 Removal...1233
5.4.1 Removing the Door Trim...1233
5.4.2 Removing the Front Door Window Regulator...1234
5.4.3 Removing the Front Door Locking System...1237
5.4.4 Removing the Outside Mirror Stay Assembly...1238
5.4.5 Removing the Front Door Panel Assembly...1238
5.5 Installation...1241
5.5.1 Installing the Front Door Panel Assembly...1241
5.5.2 Installing the Outside Mirror Stay Assembly...1243
5.5.3 Installing the Front Door Locking System...1244
5.5.4 Inspection and Adjustment After Installation of the Front Door Locking System...1245
5.5.5 Installing the Front Door Window Regulator...1246
5.5.6 Installing the Door Trims...1249
6. Seats, Seat Belts and Floor Mat...1250
6.1 Specifications...1250
6.2 Service Standards...1250
6.3 Removal...1251
6.3.1 Removing the Seats...1252
6.3.2 Removing the Seat Belts...1253
6.3.3 Removing the Floor Mats...1254
6.4 Installation...1255
6.4.1 Installing the Floor Mats...1256
6.4.2 Installing the Seat Belts...1256
6.4.3 Installing the Seats...1258
7. Trim...1260
7.1 Specifications...1260
7.2 Removal...1260
7.3 Installation...1263
8. Instrument Panel...1266
8.1 Service Standards...1266
8.2 Removal...1267
8.3 Installation...1279
8.4 Post-Installation Operation...1291
9. Wiper and Washer...1292
9.1 Service Standards...1292
9.2 Removal...1292
9.3 Installation...1295
9.4 Post-Installation Inspection...1298
10. Cab and Associated Parts...1299
10.1 Service Standards...1299
10.2 Removal...1299
10.3 Installation...1305
10.4 Post-Installation Inspection...1311
11. Silencer and Enclosure...1312
11.1 Removal...1312
11.2 Installation...1313
Group 54 - Chassis Electrical...1315
Table of Contents...1316
1. Troubleshooting...1317
2. Chassis Electrical...1322
2.1 Specifications...1322
2.2 General Description...1322
2.3 Wiring Harness...1323
2.4 Centralized Ground Connections...1325
3. Battery...1326
3.1 Specifications...1326
3.2 Service Standards...1326
3.3 General Description...1326
3.4 Removal...1327
3.5 Inspection...1328
3.6 Installation...1329
4. Fuses and Relays...1330
4.1 Specifications...1330
4.2 Service Standards...1331
4.3 General Description...1332
4.4 Removal and Installation...1333
4.5 Inspection...1334
4.5.1 Fuses...1334
4.5.2 Relays...1334
5. Fusible Link...1338
5.1 Specifications...1338
5.2 General Description...1338
5.3 Removal and Inspection...1338
5.4 Installation...1339
6. Starter Switch and Cold Start Switch...1340
6.1 Specifications...1340
6.2 General Description...1340
6.3 Removal and Installation...1341
6.4 Inspection...1341
7. Steering Column Switches...1342
7.1 Specifications...1342
7.2 General Description...1342
7.3 Inspection...1343
8. Lighting System...1344
8.1 Specifications...1344
8.2 Service Standards...1344
8.3 General Description...1345
8.3.1 Lamps and Switches...1345
8.3.2 Circuit Description...1348
8.4 Removal...1359
8.5 Inspection...1361
8.6 Installation...1363
8.7 Inspection and Adjustment After Installation...1365
9. Meters and Gauges...1367
9.1 Specifications...1367
9.2 Service Standards...1368
9.3 General Description...1369
9.4 Removal...1373
9.5 Inspection...1377
9.6 Installation...1381
9.7 Inspection After Installation...1385
10. Indicator and Warning Lamp System...1387
10.1 Specifications...1387
10.2 Service Standards...1387
10.3 General Description...1388
10.3.1 Function of Each Lamp...1388
10.3.2 Operation of Each Lamp...1390
10.4 Removal and Installation...1395
10.5 Inspection...1396
11. Exhaust Brake System (Vehicles with Manual Transmission)...1401
11.1 Specifications...1401
11.2 Service Standards...1401
11.3 General Description...1402
11.4 Removal and Installation...1404
11.5 Inspection...1405
11.6 Inspection After Installation...1406
12. Wiper and Washer System...1407
12.1 Specifications...1407
12.2 Service Standards...1407
12.3 General Description...1408
12.3.1 Wiper System...1408
12.3.2 Washer System...1411
12.4 Removal and Installation...1411
12.5 Inspection and Cleaning...1412
12.6 Inspection and Adjustment After Installation...1414
13. Substarter System...1416
13.1 General Description...1416
13.2 Removal and Installation...1417
13.3 Inspection...1417
14. Horn...1418
14.1 Specifications...1418
14.2 General Description...1418
14.3 Removal and Installation...1419
14.4 Inspection...1419
14.5 Inspection After Installation...1419
15. Radio (Option), Cassette Stereo (Option), Speakers, and Antenna...1420
15.1 Specifications...1420
15.2 General Description...1421
15.3 Removal and Installation...1422
15.4 Inspection and Adjustment...1423
16. Cigarette Lighter...1425
16.1 Specifications...1425
16.2 Service Standards...1425
16.3 General Description...1425
16.4 Removal and Installation...1426
16.5 Inspection...1426
16.6 Inspection After Installation...1427
Group 55A - Air Conditioner...1428
Group 55A (9402) - Air Conditioner...1429
Table of Contents...1430
1. Specifications...1431
2. Outlines of Refrigeration System...1432
2.1 Air System...1432
2.2 Refrigerating Cycle...1432
2.3 Electrical System...1433
3. Construction...1434
3.1 Engine Compartment...1434
3.2 Cab...1434
3.3 Control System...1435
3.4 Compressor and Magnetic Clutch...1438
3.4.1 Compressor...1438
3.4.2 Check Valve...1439
3.4.3 Magnetic Clutch...1439
3.5 Condenser...1439
3.6 Receiver Drier...1439
3.7 Cooling Unit...1440
3.8 Expansion Valve...1440
3.9 High Pressure Switch...1441
3.10 Power Relay...1441
3.11 A/C Switch...1441
3.12 Thermo Sensor...1441
4. Troubleshooting...1442
4.1 General Precautions...1442
4.2 Trouble, Cause and Remedy...1443
4.3 Inspection Procedures...1445
4.3.1 A/C Switch...1445
4.3.2 High Pressure Switch...1445
4.3.3 Thermo Sensor...1446
4.3.4 Magnetic Clutch...1446
4.3.5 Refrigerant Charge...1446
4.3.6 Receiver Drier Assembly...1447
4.3.7 Belt Tension...1447
4.3.8 Expansion Valve...1447
4.3.9 Compressor...1448
4.3.10 Air Inclusion in Refrigerant Circuit...1448
4.3.11 Moisture Inclusion in Refrigerant Circuit...1448
5. Removal and Installation...1449
5.1 Precaution for Removal and Installation...1449
5.2 Removal...1449
5.2.1 Inside the Engine Compartment...1449
5.2.2 Inside the Cab...1450
5.3 Installation...1453
6. Treatment After Installation...1454
6.1 Check and Adjustment...1454
6.2 Refrigerant Charge...1454
6.2.1 Installation of Charge Equipment...1454
6.2.2 Refrigerant Charge and Leak Check...1455
6.2.3 Removal of Charge Equipment...1455
6.3 Gas Charge...1456
6.4 Checking the Refrigerant Level...1456
6.5 Performance Test...1457
6.5.1 Preparation...1457
6.5.2 Stationary Performance Test...1457
7. Cooling Unit...1458
7.1 Components...1458
7.2 Cautions in Disassembling...1459
7.3 Disassembling...1459
8. Maintenance...1460
9. Compressor...1461
9.1 Disassembling the Clutch...1461
9.2 Reassembly the Clutch...1462
9.3 Disassembling the Shaft Seal...1463
9.4 Reassembly the Shaft Seal...1464
9.5 Special Tool Figure...1466
Group 55A (9106) - Air Conditioner...1469
Table of Contents...1470
1. Specifications...1471
2. Outlines of Refrigeration System...1472
2.1 Air System...1472
2.2 Refrigerating Cycle...1472
2.3 Electrical System...1473
3. Construction...1474
3.1 Engine Compartment...1474
3.2 Cab...1474
3.3 Control System...1475
3.4 Compressor and Magnetic Clutch...1478
3.4.1 Compressor...1478
3.4.2 Check Valve...1479
3.4.3 Magnetic Clutch...1479
3.5 Condenser...1479
3.6 Receiver Drier...1479
3.7 Cooling Unit...1480
3.8 Expansion Valve...1480
3.9 High Pressure Switch...1481
3.10 Power Relay...1481
3.11 A/C Switch...1481
3.12 Thermo Sensor...1481
4. Troubleshooting...1482
4.1 General Precautions...1482
4.2 Trouble, Cause and Remedy...1483
4.3 Inspection Procedures...1485
4.3.1 A/C Switch...1485
4.3.2 High Pressure Switch...1485
4.3.3 Thermo Sensor...1486
4.3.4 Magnetic Clutch...1486
4.3.5 Refrigerant Charge...1486
4.3.6 Receiver Drier Assembly...1487
4.3.7 Belt Tension...1487
4.3.8 Expansion Valve...1487
4.3.9 Compressor...1488
4.3.10 Air Inclusion in Refrigerant Circuit...1488
4.3.11 Moisture Inclusion in Refrigerant Circuit...1488
5. Removal and Installation...1489
5.1 Precaution for Removal and Installation...1489
5.2 Removal...1489
5.2.1 Inside the Engine Compartment...1489
5.2.2 Inside the Cab...1490
5.3 Installation...1493
6. Treatment After Installation...1494
6.1 Check and Adjustment...1494
6.2 Refrigerant Charge and Leak Check...1494
6.2.1 Installation of Charge Equipment...1494
6.2.2 Refrigerant Charge and Leak Check...1495
6.2.3 Removal of Charge Equipment...1495
6.3 Gas Charge...1496
6.4 Checking the Refrigerant Level...1496
6.5 Performance Test...1497
6.5.1 Preparation...1497
6.5.2 Stationary Performance Test...1497
7. Cooling Unit...1498
7.1 Components...1498
7.2 Cautions in Disassembling...1499
7.3 Disassembling...1499
8. Maintenance...1500
9. Compressor...1501
9.1 Disassembling the Clutch...1501
9.2 Reassembly the Clutch...1502
9.3 Disassembling the Shaft Seal...1503
9.4 Reassembly the Shaft Seal...1504
9.5 Special Tool Figure...1506
Group 55B - Heater...1509
Table of Contents...1510
1. Troubleshooting...1511
2. Heater and Ventilation...1512
2.1 Specifications...1512
2.2 Service Standards...1512
2.3 General Descriptions...1513
2.4 Wiring Diagram...1516
2.5 Pre-Removal Inspection...1517
2.5.1 Blower Switch Inspection...1517
2.5.2 Mode Control Lever Inspection...1518
2.5.3 Temperature Control Lever Inspection...1520
2.5.4 Air Selector Lever Inspection...1521
2.5.5 Side Ventilator Inspection...1522
2.6 Removal...1523
2.7 Installation...1528
2.8 Post-Installation Adjustments...1532
3. Heater Plumbing...1534
3.1 Removal...1534
3.2 Inspection...1535
3.3 Installation...1535
